Catalytic reactor charging system and method for operation thereof

ABSTRACT

A catalyst loading system for utilizing catalyst from a bulk supply located adjacent but not on the upper tube sheet of a catalytic reactor and for mechanized measuring of multiple identical quantities of catalyst and for mechanized loading of catalyst pellets into the reaction tubes of the reactor to achieve even drop rate, compaction and outage of the reaction tubes. From the bulk supply, multi-compartment catalyst charging hoppers are individually filled in rapid and accurately measured fashion by mechanized filling equipment having a predetermined sequence of operation that ensures accuracy of volumetric catalyst measurement. The charging hoppers are used for delivery of measured volumes of catalyst of a reactor tube loading mechanism which may take the form of a mobile cart framework being selectively positionable relative to the upper tube sheet and reaction tubes of a catalytic reactor to be charged with catalyst pellets. A pair of electronic vibrators are mounted to the cart framework and provide for support and vibratory movement of a vibratory tray having a catalyst feed hopper adapted to feed catalyst pellets to a plurality of generally parallel catalyst transfer troughs along which catalyst pellets are moved by vibration of the vibratory tray to a plurality of drop tubes. A compartmented hopper is fixed to the vibratory tray and controllably feeds catalyst pellets into respective catalyst transfer troughs. A plurality of charging tubes are connected to respective drop tubes by a plurality of elongate flexible tubes and are maintained in fixed, spaced relation by a structural element so as to define a charging manifold for simultaneous, timed delivery of catalyst pellets into a plurality of reactor tubes. The charging manifold has locator pins which are inserted into selected reactor tubes for orienting the charging tubes of the charging manifold with respect to a selected group of reaction tubes. A system is also provided for raising and lowering the charging manifold for efficiency of reactor tube charging operations. An electronic control system is effective for controlling the vibrators to achieve even drop rate from each of the catalyst transfer troughs and to control the vibrators responsive to catalyst weight to achieve even catalyst drop rate during an entire catalyst charging cycle.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates generally to the controlled filling of thecatalyst tubes of catalytic reactors with catalyst materials when thereactors are placed into service or when they have been cleaned of spentcatalyst materials in preparation for further use in processes requiringcatalytic reaction of flowing products of the process. Moreparticularly, the present invention concerns a mechanized catalyticreactor charging system including a loading cart that is used by reactorservicing personnel and which is effective for efficient and controlledand simultaneous charging of a plurality of the reaction tubes of acatalytic reactor so that each of the plurality of reaction tubes willcontain a precise measured quantity of the catalyst arranged in one ormore layers and having a predetermined degree of compaction. Evenfurther, the present invention concerns a mechanized catalyst loadingcart having the capability for automatically adjusting the amplitude ofvibratory movement of a dispensing control tray thereof with respect tothe weight of catalyst material contained therein for dispensing, so asto ensure the consistent measured and timed dispensing of the catalystmaterial during a complete dispensing cycle of the loading cart. Thisinvention also concerns a method and apparatus for the mechanizedfilling of catalyst charging hoppers at a location remote from the tubesheet of the reactor and for efficiently and safely charging thecatalyst loading cart with catalyst material from the catalyst charginghoppers.

[0003] 2. Description of the Prior Art

[0004] Although, for the purpose of discussing the preferred embodimentof the invention disclosed herein, the present invention is discussedparticularly as it relates to the dispensing of measured quantities ofcatalyst material into the reaction tubes of catalytic reactors, itshould be borne in mind that the invention may be employed for thedispensing of measured quantities of other materials for other purposes.Thus the scope of the present invention is not intended to be limited bythe specific discussion of the preferred embodiment, but rather thepreferred embodiment of this invention is intended only as arepresentative example that comes within the spirit and scope of theinvention.

[0005] In a chemical plant the desired chemical is generallymanufactured with the use of a tube and shell type catalytic reactor.The typical catalytic reactor is a cylindrical structure approximately15′ in diameter and can be 100′ or so in height (all catalytic reactorsare custom designed and built for a particular chemical process and thuscan have a wide range of diameters and heights). The reactor istypically in the form of a cylindrical shell having domed and flangedtop and bottom ends that are unbolted and removed to permit servicing ofthe reactor. A multiplicity of reaction tubes are typically locatedvertically in the reactor and have upper and lower ends that are weldedto upper and lower tube sheets that extend transversely of the reactorshell and are located adjacent the end flanges of the reactor shell. Thereaction tubes are typically in the order of 1″ in diameter and arewelded to the tube sheets in a geometric pattern. A worker standing onthe upper tube sheet will visualize a flat sheet having a multiplicityof holes arranged in a geometric pattern and being about ½″ apart, witheach hole having a weld bead about it for connection of the upper tubeend to the upper tube sheet.

[0006] One or more types of catalyst material is loaded into each of thereaction tubes and is provided in the form of small spheres or cylindersin the range of from {fraction (1/16)}″ to ½″ in diameter. The catalystpellets are typically composed of ceramic or alumina material that iscoated with a reactive agent for the process that is intended. Uponactivation in the presence of a fluid flowing through the reaction tubesthe catalyst reacts with the flowing fluid to give off a derivativeproduct. Generally, the catalyst is loaded into the reaction tubes (someup to 20,000 tubes) in zones or layers. That is to say, if the reactiontube is 60′ in height, catalyst “A” would comprise a 20′ zone, catalyst“B” would comprise a second 20′ zone and catalyst “C” would comprise athird 20′ zone. The loading rate of the catalyst into these tubesdetermines the compaction of the catalyst within the tubes. This isreferred to as “drop time”. The space remaining within the tubes whichis above the upper end of the catalyst is referred to as “tube outage”.Ideally, if all (20,000) tubes have the same “drop time” during chargingor loading thereof, the tube outage (the balance of unfilled tube) willbe uniform. When the reactor tubes are all charged uniformly it willyield the best reactor performance, i.e., the best quality and quantityof resulting chemical product.

[0007] At the present time most catalyst loading or charging operationsare conducted by completely manual activities, with workers using afunnel to direct catalyst pellets into a selected reaction tube as thecatalyst is poured by hand from small premeasured bags. It is well knownthat each worker of a charging crew will typically pour catalyst pelletsat a slightly different rate so that the result can often be poor droptime uniformity thus resulting in uneven tube outages. In some cases thecatalyst pellets will bridge within some of the reaction tubes due tonon-uniform drop time and catalyst compaction, thus resulting in voidsthat cause “hot spots” and uneven fluid pressures and temperatureswithin the various tubes of the reactor. The resulting chemical productfrom reactors that have not been uniformly charged with catalyst isoften less than optimum quality.

[0008] Various attempts have been made to provide a mechanized catalystloader and method of filling catalytic reactor tubes with pellets ofcatalyst materials. One example is presented by U.S. Pat. No. 3,223,490of Sacken, et al wherein a plate is drilled to the same pattern as theholes of the reactor tubes and corresponding fill tubes are dependentfrom the plate so as to be loosely received within respective reactortubes. The catalyst material is then dropped through the fill tubes intothe reactor tubes until the level of the catalyst in each of the reactortubes reaches the level of the fill tubes. Thereafter, the plate and itsfill tubes are lifted so that the remaining catalyst pellets in each ofthe fill tubes will be deposited into the reaction tubes. This type ofcontrolled filling achieves virtually the same catalyst bed height ineach of the reactor tubes but it does not take into consideration theproblem of catalyst pellet bridging and compaction within the respectivereaction tubes. Thus, though the upper end of the catalyst beds in thetubes can be virtually the same, voids within part of the reaction tubeswhich occurs by uncontrolled drop rate will result in uneven catalystmaterials in the catalyst beds. Further, this method does not providefor consistent drop rate of the catalyst so that uneven tube outage andnon-uniform compaction can be the result. This could result in thedevelopment of hot spots within the reactor which could be detrimentalto reactor operation. Also, since virtally every reactor is “customdesigned” so its height, diameter and number of catalyst reactor tubescan vary, clearly the catalyst loader shown in this patent must also be“custom designed”, for the reactor hole pattern and dimension of thereactor. Thus, a catalyst loader of this nature would need to bededicated to this particular reactor so that a catalyst loader would beneeded for each reactor. It is desirable therefore to provide forcatalyst loading operations by means of mechanized catalyst loadingwhich is readily adjustable to the hole pattern and tube dimension ofvarious types of catalytic reactors.

[0009] A catalyst loading cart mechanism is presented by U.S. Pat. No.4,402,643 of Lytton, et al which has a plurality of catalyst storagehoppers each feeding a respective slot of a vibratory tray, with thecatalyst pellets dropping from the tray into respective flexibleconduits that are engaged within the upper openings of a plurality ofreaction tubes. This apparatus has proved ineffective because thevibratory activity of the tray does not ensure precision control of thedrop rate of the catalyst pellets from each of the feed grooves of thetray. Use of this apparatus has been discontinued as ineffective forsimultaneous loading of multiple catalytic reactor tubes.

[0010] Another prior art reactor tube loading device is disclosed byU.S. Pate. No. 4,701,101 of Sapoff, wherein a catalyst loading funnel isprovided having a plurality of generally triangular storage chamberswhich feed catalyst fill tubes that are inserted into the openings of aplurality of reaction tubes. The funnel mechanism may be supported by awheeled cart and provided with flexible tubes having tubular spouts atthe lower ends thereof which are received within the openings of aplurality of reaction tubes. The drop rate of the catalyst material isintended to be adjustable by adjusting the speed of rotation of meteringrods or by raising and lowering metering rods in each funnel module toincrease or decrease the speed of catalyst drop.

[0011] Although catalytic reactors for chemical processes may takevarious forms, for purposes of the present invention the reactors ofparticular concern are fixed bed type catalytic reactors having anexternal housing or shell of considerable height within which is mounteda multiplicity of reaction tubes, the tubes being supported at the upperand lower ends thereof by means of tube sheets. The reaction tubes mayalso be provided with intermediate support if appropriate for thestructural integrity of the reactor mechanism. The catalytic reactorstypically utilized in the petroleum and petrochemical industriestypically employ reactor tubes having an internal diameter in the orderof one inch and a length in the order of from 60′ to 100′ or more.Depending upon the character of the reaction to occur, the reactor tubesmay be filled to a predetermined level with pellets of catalyst materialso that the outage (the space above each tube bed of catalyst) will besubstantially the same. In many cases, each reactor tube will containtwo or more catalyst materials each arranged to a predetermined filllevel. For efficient operation of catalytic reactors, each of thereaction tubes should be loaded with catalyst pellets in precisely thesame way so as to obtain consistency of catalyst arrangement andcompaction within each of the reaction tubes. Typically, catalyticreactors are loaded or charged by means of a highly labor intensivemanual loading operation. In this case, workers are present at the uppertube plate of the reactor, where the openings of the multiple reactiontubes are exposed. These workers utilize funnels having lower dischargetubes that are inserted into the tube opening of a reaction tube to befilled. These tube filling personnel are typically trained to depositreactor pellets into the funnel and thus, into the reaction tube inaccordance with a predetermined quantity input which is referred to as“drop time” or “drop rate”. If the quantity input of the catalyst isexceeded, it is possible that the catalyst pellets can bridge within thetubes, thereby developing voids in the catalyst beds of some of thetubes and thus resulting in uneven outage at the upper ends of some ofthe tubes. The character of catalyst input to the various tubes of areactor is also determined by the character of the catalyst beingloaded. Catalyst materials are provided in spherical pellets of varioussize and are also provided in cylindrical pellets of varying size. Therespective pellets whether cylindrical or spherical must be dropped intothe tubes in accordance with a particular timing sequence “drop time” sothat the resulting catalyst bed in each of the tubes will be virtuallythe same and the outage at the tops of the tubes will also be virtuallythe same.

[0012] The upper and lower ends of a cylindrical reactor shell aretypically closed by means of domed closures that are secured by bolts toupper and lower connector flanges of the reactor shell. For catalystloading, the upper domed closure is typically unbolted from the catalystshell, is lifted therefrom by means of a crane and is typically loweredto the ground until the tube filling procedure has been completed. Tofacilitate loading of the catalyst materials into the multiple reactiontubes of a catalytic reactor, a temporary “working compartment” ofsufficient height for a worker to stand on the upper tube sheet of areactor is assembled to the upper end of the reactor shell. Thisenclosure is typically air-conditioned for the comfort of workers and isprovided with a dust removal system to ensure as much as possible thatcatalyst dust, that is typically liberated into the atmosphere duringthe charging operation, is continuously removed from the workingenclosure. Further, the workers engaged in the loading operationtypically wear sealed outer garments that prevent the catalyst dust fromcoming into contact with the worker's skin and also wear ventilationequipment to ensure the that the catalyst dust is not breathed by theworkers.

[0013] Obviously, manual loading of catalyst materials by means offunnels as is currently done, is subject to many disadvantages. Forexample, the labor requirements for a manual catalyst loading operationadd significant cost to the reactor and thus add to the cost of theresulting product. It is therefore desirable to provide for mechanizedcatalyst loading operations that significantly minimize labor costs.Since hand loading of catalyst materials is subject to wide variation ofdrop time, catalyst compaction, etc., depending upon the catalystmaterials being used and the workers accomplishing the loadingoperation, it is desirable to provide a mechanized catalyst loadingoperation to enable precision loading of each of the catalyst tubes ofthe reactor so that the resulting catalyst bed in each of the tubes isvirtually the same and the outage between the catalyst bed and the tubesheets of the reactor is also virtually the same. Tests which have beenconducted indicate clearly that mechanized catalyst loading is muchsuperior in comparison with hand loading of catalyst materials becausethe drop rate of the catalyst materials can be efficiently controlled sothat the drop rate is the same with each of the catalyst materialswithin each of the reaction tubes.

[0014] From the inventor's studies concerning loading operations forcatalytic reactors, virtually any phase of the catalyst handling andreactor loading operations where manual operations are used, the resultsof such operations can be improved by mechanization, thus achievingrepeatability and better productivity. Thus, according to the presentinvention is desirable to provide a catalyst handling, measuring andcatalytic reactor charging system that as much as possible takesadvantage of mechaniztion and minimizes the manual-aspects of catalyticreactor servicing operations.

SUMMARY OF THE INVENTION

[0015] It is a principal feature of the present invention to provide anovel mechanized catalyst handling, measuring and reactor tube chargingsystem that permits efficiency and accuracy of catalyst measuring from abulk catalyst supply located remote from the upper tube sheet of acatalytic reactor being charged and controlled dispensing of catalystpellets into multiple reactor tubes in such manner that drop time,catalyst compaction and tube outage are consistent in all of the reactortubes.

[0016] It is also a feature of the present invention to provide anovelized catalyst loading cart having the capability for use in theloading of catalyst material in catalytic reactors in virtually anysize, design or tube pattern.

[0017] It is another feature of this invention to provide a novelcatalyst loading cart having the capability of efficiently feedingcatalyst pellets into the upper ends of the catalyst reaction tubes inaccordance with a precision predetermined drop rate for insuring thatthe catalyst beds are virtually the same in each catalytic reactor tubeand that no catalyst voids are present within any of the reaction tubes.

[0018] It is a even further feature of the present invention to providea novel catalyst loading cart for catalytic reactors having multiplecatalyst charging tubes that are provided with lower charging fittings,with the fittings being supported by a charging manifold structure andarranged for simultaneous insertion of the open upper ends of aplurality of reaction tubes so that multiple reaction tubes can besimultaneously charged with catalyst.

[0019] It is an even further feature of the this invention to provide anovel catalyst loading cart having a wheeled cart framework which can beraised relative to caster wheels which permit the cart to be movable onthe tube sheet of the reactor and which can be lowered relative to thecaster wheels to provide for stable support of the cart on the tubesheet of the reactor or on a cover panel that might be provided to coverappropriate portions of the tube sheet.

[0020] It is another feature of this invention to provide a novelcatalyst loading cart mechanism having a mobile cart framework forsupport of a vibratory catalyst transfer tray, and wherein a chargingmanifold is provided that is vertically moveable relative to the cartframework to provide for controlled positioning of catalyst dischargeopenings of the manifold in charging registry with a selected group ofthe reaction tubes for simultaneous charging thereof with catalystmaterial.

[0021] It is an even further feature of this invention to provide anovel catalyst loading cart having a vibratory catalyst transfer traywith a plurality of catalyst transfer troughs or grooves through whichcatalyst material is conducted to a plurality of drop tubes and whereina pair of electronically energized vibratory for the vibratory tray areeach individually amplitude adjustable responsive to ensure uniformityof catalyst discharge from each of the slots of the tray so that thedrop rate of catalyst into each of the plurality of reaction tubes beingcharged will be uniform.

[0022] It is another feature of the present invention to provide amechanized catalyst loading cart having an adjustable feed hopper withmultiple catalyst chambers, one for each catalyst transfer trough of avibratory tray and wherein the amplitude of vibration of the tray isautomatically adjustable responsive to the weight of catalyst within thehopper so that the rate of delivery of catalyst material to the droptubes of the tray during a charging cycle will not change as thecatalyst material is dispensed and the weight of the catalyst within thehopper decreases.

[0023] It is also a feature of the present invention to provide amechanized catalyst loading cart having a multi-compartment catalysthopper from which catalyst is fed at a uniform drop rate from each ofthe hopper compartments and further having at least one portablecharging hopper which also has multiple compartments of identical sizeand which is filled with catalyst at a location remote from the uppertube sheet of a reactor and, after being closed to secure the catalystcontained therein, is carried to a catalyst loading cart, positioned onthe upper tube sheet of the reactor and positioned in charging assemblywith the hopper of the cart and is manipulated to discharge the measuredcontents of the compartments thereof into the respective compartments ofthe loading cart hopper without any risk of spillage.

[0024] Among the several features of the present invention iscontemplated the provision of mechanized apparatus for efficiently,accurately and quickly filling all of the multiple compartments of aportable charging hopper with substantially identical quantities ofcatalyst, so that the hopper of the catalyst loading cart can itself becharged with accurately measured quantities of catalyst in therespective charging chambers of the apparatus and can do so quickly andefficiently and with minimal labor costs.

[0025] Briefly, the various objects and features of the presentinvention are realized through the provision of a mechanized catalystloading cart of mobile nature which is used at the upper tube sheet of acatalytic reactor for the purpose of charging the multiple reactiontubes of the reactor with one or more types of catalyst pellets. In eachembodiment of the present invention, the catalyst loading cart includesa vibratory tray having a plurality of tray troughs or grooves thatconduct catalyst pellets from the tray into a plurality of flexiblecatalyst delivery tubes that direct the falling catalyst pellets intorespective reaction tubes of the reactor. One delivery tube will beprovided for each of the catalyst troughs or grooves of the tray. Attheir lower ends, the delivery tubes are fixed to a charging manifoldhaving a plurality of depending charging tubes of sufficiently smalldimension as to enter within the small diameter openings of the reactiontubes. The charging tubes are arranged according to the pattern andspacing of the reaction tubes to be charged. The charging manifold isprovided with a pair of manifold locators that enter tube openings atthe tube sheet and provide for orientation of the manifold and theplurality catalyst charging tubes so that the charging tubes will entera selected group of reaction tubes for the purpose of catalyst charging.The vibratory tray is provided with a hopper having a plurality ofcatalyst compartments, one for each of the catalyst transfer troughs orslots of the tray. Catalyst material is metered from each of thecatalyst compartments by means of an adjustable weir having a pluralityof weir gates thereon which extend into respective transfer troughs andcontrol delivery of catalyst pellets from the respective hoppercompartments to the transfer troughs.

[0026] The vibratory tray is vibrated by means of two or moreelectrically energized vibrators that are each amplitude adjustable bymeans of electronic trimmer circuits. By adjusting individualpotentiometers of the trimmer circuits, a user can achieve substantiallyeven delivery of catalyst pellets from each of the plurality of catalysttroughs of the vibratory tray. This feature overcomes a disadvantage ofthe prior art, because a single vibrator cannot ordinarily be adjustedto provide even dispensing of catalyst pellets from each of the troughsof a vibratory tray.

[0027] For optimum delivery of catalyst pellets into a plurality ofreaction tubes, a predetermined catalyst drop rate is established whichis sufficiently high to achieve efficient production and is not highenough to result in bridging or improper compaction of catalyst pelletswithin respective reaction tubes. It has been determined, however thatthe feed rate of catalyst pellets from a vibratory tray having amultiple chamber hopper associated therewith will typically changeduring a catalyst charging cycle as the result of decreasing catalystweight. The amplitude of vibration of a vibratory tray will typicallychange from the time dispensing begins, when the hopper compartments arefull of catalyst pellets, to the time when the total charge of catalysthas been depleted. The vibratory tray will be vibrated at a desiredamplitude when catalyst dispensing begins, but as the weight of thecatalyst decreases within the hopper compartments, the vibratoryamplitude of the tray will be increased simply because the weight of thedispensed catalyst is not present and thus the mass of the vibratorytray and its contents becomes less as the catalyst dispensing cycleprogresses. It is desirable, therefore to provide for vibration of acatalyst transfer tray which is minimally influenced by changes in theweight or mass of the transfer tray and its contents. This feature isprovided by an electronically controlled system which automaticallyadjusts the electrical power to the vibrators to compensate for reducedweight so that the rate of catalyst delivery from the hopper through thetransfer tray will remain substantially the same as the catalyst pelletcharge is depleted during dispensing. A solution of this problem isachieved by the provision of an accelerometer regulated amplitudecontrol system which senses the amplitude of vibration of the vibratorytray and provides electronic signals responsive thereto. These weightrelated electronic signals are then conditioned and fed to vibratorcontrol circuitry to automatically trim the electrical power supply tothe vibrators as needed to maintain a substantially constant rate oftray vibration and thus maintain an substantially constant rate ofcatalyst pellet drop from the catalyst transfer troughs during acomplete catalyst charging cycle. Thus, the delivery of catalyst pelletsto the reactor tubes is not significantly altered by the decreasingweight of catalyst during a catalyst charging sequence.

[0028] Since catalyst materials have been determined to havecarcinogenic characteristics requiring workers during catalyst loadingoperations to wear sealed clothing and ventilation systems, thevibratory tray is provided with a vacuum hood and a vacuum tray so thatany catalyst dust or tailings liberated from the catalyst pellets willbe removed by the vacuum for disposal. Thus the loading cart apparatusassists in maintaining the working environment for the catalyst loadingoperation substantially free of catalyst dust and tailings.

[0029] To ensure against inadvertent spillage of catalyst pellets ontothe upper tube sheet and thus into the reaction tubes during charging ofthe loading cart hopper with catalyst and to further ensure simple andefficient charging of each of the loading cart hopper compartments withmeasured quantities of catalyst a portable charging hopper is provided.This charging hopper is provided with the same number of measuringcompartments as the compartments of the loading cart hopper and isprovided with a movable bottom wall gate for simultaneous dumping of thecontents of its compartments into the respective compartments of theloading cart hopper. Each of the various catalyst compartments of thecharging hopper is of virtually the same dimension, thus by simplypouring catalyst pellets into all of the compartments and wiping awaythe excess in precisely the same manner at each loading of the charginghopper, assurance is provided that each of the measuring compartments ofthe charging hopper contains virtually the same quantity of catalystpellets. The charging hopper is filled at a catalyst source locationthat is remote from the upper tube sheet of the reactor and is carriedmanually to the loading cart and placed in assembly with the loadingcart hopper. Its bottom wall gate is then moved to its open position fordumping the measured catalyst of each of the charging hoppercompartments into respective compartments of the loading cart hopper.Further, by providing a charging hopper loading machine for mechanizedloading of the charging hopper, virtually the same total volume ofcatalyst material can be discharged from the charging hopper into thedispensing hopper of the loading cart during each dispensing cycle. Thecharging hopper loading machine receives an empty charging hopper and,upon activation of its mechanism, the machine moves the empty charginghopper to a position for filling and opens a gate of its catalyst hopperand, while being vibrated, discharges a sufficient volume of catalystpellets onto the upper portion of the charging hopper to overfill eachof the measuring compartments thereof As the machine then returns theoverfilled charging hopper to the start position a leveling brush, whichmay be statically located or movable, i.e., rotatable, will remove theexcess catalyst pellets, thus leaving the multiple measuringcompartments of the charging hopper with a precisely volumetricallymeasured quantity of catalyst. The filled charging hopper is then closedand latched to ensure against spillage and is carried from the loadingfacility to the catalyst loading cart and assembled with the hopper ofthe cart. When the lower gate of the charging hopper is then opened thevolumetrically measured catalyst of each of the charging hoppercompartments will descend into respective dispensing compartments of thehopper of the cart. The net result, therefore, is the systematized, lowcost, accurate charging of the multiple tubes of a catalytic reactor,thus providing optimum results from the reactor charging procedure andat the same time providing significant labor savings as compared toconventional manual reactor servicing operations.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The various objects and advantages of this invention will becomeapparent to those sidled in the art upon an understanding of thefollowing detailed description of the invention, read in light of theaccompanying drawings which are made a part of this specification and inwhich:

[0031]FIG. 1 is a side elevational view of a catalyst loading cartrepresenting a preferred embodiment of the present invention;

[0032]FIG. 2 is an end view of the catalyst loading cart taken alongline 2-2 of FIG. 1;

[0033]FIG. 3 is a plan view of the catalyst loading cart of FIGS. 1 and2;

[0034]FIG. 4 is a partial sectional view of the catalyst chargingmanifold of the apparatus shown in FIGS. 1-3;

[0035]FIG. 5 is an elevational view of the charging manifold of FIG. 4;

[0036]FIG. 6 is a plan view of the charging manifold of FIGS. 4 and 5;

[0037]FIG. 7 is an isometric illustration of a vacuum type vent hoodthat is mounted above the catalyst transfer tray and which serves toremove catalyst dust that might be present in the tray;

[0038]FIG. 8 is a elevational view of the catalyst dust hood of FIG. 7;

[0039]FIG. 9 is an end view of the catalyst dust hood of FIGS. 7 and 8;

[0040]FIG. 10 is an isometric illustration of a vacuum type dust panthat is mounted below the catalyst transfer tray and in registry withdust tailing openings of the catalyst transfer troughs for the purposeof removing the catalyst tailings or dust as the catalyst pellets movethrough the troughs of the tray;

[0041]FIG. 11 is an end view of the catalyst dust pan of FIG. 9 and 10;

[0042]FIG. 12 is a plan view of the catalyst dust pan of FIGS. 9-11;

[0043]FIG. 13 is a side elevational view of the catalyst dust tray ofFIGS. 9-12;

[0044]FIG. 14 is a side elevational view of a catalyst loading cartrepresenting an alternative embodiment of the present invention whereina lower charging manifold thereof is subject to controllable raising andlowering relative to the reaction tube openings to be charged thereby,

[0045]FIG. 15 is an electronic schematic illustration of a portion ofthe control circuitry for the catalyst loading cart of the presentinvention illustrating the vibration trimmer system and the automaticaccelerometer controlled trimming circuitry for controlling vibrationcharacteristics of the vibratory tray responsive to catalyst weight;

[0046]FIGS. 16 and 17 are electrical layout illustrations showingfeatures of the electronic control circuitry for the catalyst loadingcart of this invention;

[0047]FIG. 18 is an isometric illustration of a catalyst charging hopperwhich is utilized to quickly transfer measured quantities of catalystpellets to the respective hopper compartments of the catalyst loadingcart;

[0048]FIG. 19 is an end elevational view of the catalyst charging hopperof FIG. 15 showing its position relative to the hopper structure forcharging the hopper compartments with catalyst material;

[0049]FIG. 20 is a front elevational view of an automated mechanism foraccurately loading a catalyst charging hopper so that each of themultiple measuring compartments of the catalyst charging hopper willcontain virtually identical volumes of catalyst pellets;

[0050]FIG. 21 is a side elevational view of the automated catalystcharging hopper loading mechanism of FIG. 20, with the dust shroudthereof removed to enable visualization of the operational componentsthereof

[0051]FIG. 22 is a partial front elevational view of the automatedcatalyst charging hopper loading mechanism of FIGS. 20 and 21, showingthe access doors thereof in their closed positions.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

[0052] Referring now to the drawings and first to FIGS. 1-3, amechanized catalyst loading cart that in constructed in accordance withthe principles of the present invention is shown generally at 10 andincorporates a cart framework, shown generally at 12, having a wheeledbase structure shown generally at 14. The wheeled base 14 is in the formof a rectangular framework base having side members 16 and end members18 from which depend support legs 20 that are located at respectivecorners of the rectangular base. The wheeled base structure 14 isprovided with a plurality of casters 22 which enable the cart to berolled along any horizontal surface, such as the horizonal upper tubesheet of a catalytic reactor. To isolate the vibration of the loadingcart mechanism from the upper tube sheet of the reactor, cushioned feet24 are provided for each of the legs 20. These cushioned feet rest uponthe upper tube sheet of the reactor after the cart has been properlylocated for dispensing of catalyst into particular reaction tubes.

[0053] It is desirable to provide the loading cart for ease of movementon the upper tube sheet of the reactor so that the charging manifold ofthe cart, to be discussed hereinbelow, can be easily positioned withrespect to reactor tubes to be charged. This feature is accomplished byconnecting the casters 22 to the wheeled base 14 by a retractionmechanism that retracts the casters to enable the cushioned feet 24 ofthe wheeled base 14 to rest on the upper tube sheet of the catalyticreactor. The cushioning activity of the cushioned feet 24 is provided byrubber mounts which are attached to the bottom of each leg and serve toisolate the vibration of the vibratory tray to the catalyst loadingcart. Retraction of the casters 22 is accomplished by a linear motor 26which may conveniently take the form of an air energized cylinder andpiston assembly or an electrically energized linear motor or the likewhich operates through a mechanical linkage for accomplishing pivotalmovement of retraction plates 28 about respective pivots 30 thus raisingor lowering the casters which are mounted to the retraction plates. Whenthe retraction plates 28 are pivoted upwardly about their respectivepivots 30 in essence the wheeled base 14 is lowered, causing thecushioned feet 24 of the base to come into supporting contact with theupper tube sheet of the reactor. Thus, in the retracted positions of thecastors, the wheeled base 14 will be substantially immoveable withrespect to the upper tube sheet of the reactor and thus will not moveinadvertently as catalyst material is being dispensed into specificreaction tubes.

[0054] The framework 12 of the catalyst loading cart is provided with anupper moveable frame section shown generally at 32 and incorporating apair of frame connectors 34 that are connected to pivot members 36 tothus permit the frame structure 32 to be pivotally moveable relative tothe wheeled base 14. This pivotal movement may be controlled by a linearactuator 38 having its ends connected respectively to horizontal members40 of the frame 32 and to the rectangular frame 16 of the wheeled base.The frame 32 also incorporates upright members 42 that areinterconnected with the horizontal members 40 as shown in FIG. 1 and areprovided with lateral handle support members 44 to which a transversehandle 46 is connected. A worker using the wheeled mechanized catalystloading cart of this invention will grasp the transverse handle 44 andwill be able to manipulate the position of the cart relative toparticular reaction tubes of the catalytic reactor. For feeding ofpelletized catalyst material, it is desirable to contain the catalystwithin a compartmentalized hopper and to feed the catalyst material byvibration from individual compartments of the hopper to individualtroughs of a catalyst transfer tray and then to controllably drop thecatalyst pellets from the tray into individual reaction tubes at acontrolled drop rate that will ensure proper compaction of the catalystwithin the reaction tubes without allowing the catalyst material tobecome bridged and to develop voids within the reaction tubes.Accordingly, the catalyst loading cart of this invention is providedwith a pair of vibratory tray supports 48 having their lower endsconnected to the wheeled base structure 14 and having a transversemember 50 interconnecting the upper ends thereof. A pair of lateralsupport members 52 have their ends connected to the transverse supportmember 50 and provide for support of an electrical control panel module54 in the form of a generally rectangular enclosure to be discussed indetail hereinbelow.

[0055] A vibratory tray 56 is supported in generally horizontallyoriented manner by means of a pair of electronic vibrator elements 58and 60 that are each bolted or otherwise connected to a horizontalsupport structure 62 of the wheeled base 14. The horizontal support 62is positioned by a pair of upright support members 64 which are fixed tothe rectangular base framework of the wheeled base structure 14. Thevibratory tray as shown in FIG. 1 is fixed to the upper portions of eachof the vibrators 58 and 60 so that the tray is oscillated by thevibrators. The vibratory tray 56 is provided with a plurality of spacedparallel partitions 66, dividing the tray into a plurality of catalysttransfer troughs or grooves 68 shown in FIG. 3. The catalyst transfertroughs are. arranged so that at one end they are located beneath thebottom outlet opening 70 of a multi-chamber hopper 72 which is mountedsuch as by welding to the upper portion of the catalyst transfer tray.As shown in FIG. 3, the hopper 72 is provided with a plurality of spacedparallel internal partitions 74 defining a plurality of internalcatalyst chambers 76 which are arranged for discharge of catalystpellets into respective ones of the plurality of troughs or grooves 68of the catalyst transfer tray. Discharge of catalyst pellets into thetransfer troughs of the tray is controlled in part by vibration of thehopper along with the tray by the electronic vibrators 58 and 60 and inpart by an adjustable weir member 78 having a plurality of gate sections80 each arranged within one of the catalyst transfer troughs. The weirmember is adjusted upwardly or downwardly as desired relative to thecatalyst transfer troughs so as to control the effective size of thedischarge openings of the hopper compartments relative to the respectivetransfer troughs of the vibratory tray.

[0056] One of the problems that have been found with vibratory typefeeder systems for catalyst pellets or any other small objects is thatis very difficult to achieve substantially consistent vibratory feedingor transfer of objects so that the discharge from each of the troughs ofa vibratory tray is essentially the same. In the case of delivery ofcatalyst materials, it is necessary that the catalyst pellet drop timein each of the various reaction tubes of a catalytic reactor bevirtually the same. If catalyst pellets are feeding faster from one ormore troughs of the tray, the result will be uneven catalyst drop rateand thus uneven compaction of catalyst within the reaction tubes beingcharged. In this case voids can occur in certain reactor tubes bybridging of the catalyst pellets, thus resulting in differing outage ofthe tubes when the loading operation has been completed. The pressurerequired to force fluid through the reaction tubes will not be the samefor all tubes. Although vibrator apparatus may be adjustable inamplitude of vibration, it is virtually impossible to adjust theamplitude of a single vibrator device is such manner that all of thetroughs of vibratory tray can achieve essentially the same catalyst droprate. It has been determined that by providing two vibrator devices suchas shown at 58 and 60, each being connected to the cross member support62 by means of bolts 63 and by providing trimmer adjustments for eachvibrator for synchronization thereof and a master vibrator adjustmentfor simultaneously adjusting the amplitude of both vibrators to thusaccomplish precise adjustment of the drop rate of the catalyst pelletsfrom all of the troughs of the vibratory tray so that the catalystoutput of each of the transfer troughs is essentially the same. As shownparticularly in FIGS. 1 and 2, the electronic panel housing 54 isprovided with a control panel 82 having a power switch 84, a masterpotentiometer 86 for controlling electrical power input to bothvibrators and trimmer potentiometers 88 and 90 for individual control ofeach of the vibrators 58 and 60. Thus, to control the discharge rate ofeach of the troughs of the vibrator tray so that the discharge rates ofthe multiple trays are essentially identical, the trimmer adjustments 88and 90 may be individually manipulated. When each of the troughs isoutputting substantially identical volumes of catalyst pellets throughselectively controlled vibration of the vibrators 58 and 60, then thedrop rate of the catalyst pellets from the multiple troughs of the traymay be increased or decreased simply by appropriate adjustment of themaster potentiometer 86 which causes simultaneous amplitude adjustmentof both of the vibrators while the previously adjusted trimming controlis maintained.

[0057] It is desirable that the catalyst pellets that are being loadedinto the reaction tubes of the reactor be free of catalyst dust sincethe dust can interfere with fluid transition through the catalyst pelletmass and thus interfere with the optimum reaction that is designed.Catalyst pellets however are typically delivered in premeasured bags andthe bags will typically contain a small quanity of catalyist dust andtailings that will typically be introduced into the hopper compartmentsalong with the catalyist material. It is desirable to ensure that thisdust be separated from the catalyist pellets before the pellets aredropped into the reactor tubes. Even further, catalyst materials areknown to have a carcengenic characteristic; thus it is highly desirableto ensure that workers involved in catalyist loading operations areprotected against contact with catalyst dust and tailings and that theybe protected from breathing the catalyist dust. In one form of theinvention, as shown in FIGS. 1-3, the catalyist dust or tailings arecaused to drop from each of the catalyst troughs into a receptacle thatreceives and secures the catalyst tailings to prevent them frominvertially entering the reactor tubes or becoming air entrained dustthat contaminates the working environement about the catalyst loadingoperation. In another form the of the invention, as shown in FIG. 11,the loading cart is provided with a vaccum engerized dust or tailingremoval system including an evacuated trough and an evacuated hood thatcover at least a portion of the catalyst loading troughs and serve toforcefully remove the dust and tailings from the catalyist pellets sothat they can be dropped substantially clean into the reactor tubes. Infact, the catalyist loading cart of FIGS. 1-3 if desired, may beprovided with a vacuum controlled dust and tailing removal systeminstead of the gravity removal system that is shown.

[0058] As is evident from FIG. 3, the bottom surface that defines thebottom of each of the catalyist transfer troughs 68 defines amultiplicity of small openings 92 which cover only a small section ofthe length of each of the troughs. After the catalyst pellets and anydust or tailings that accompany the pellets have been deposited from thehopper compartments into the respective troughs, vibration of the traywill cause the catalyst and the dust and tailing contaminents throughtraverse along the tray until the openings 92 are reached. The dust andtailings will then fall through the multiple small openings 92 thusallowing the catalyst pellets to continue forward movement by thevibratory action of the tray to the respective discharge openings 69 ofthe catalyst transfer troughs.

[0059] As shown particularly in FIG. 1, a support post 94 projectsupwardly from a central framework section 96 of the wheeled base 14. Atransverse support member 98 has its intermediate portion connected tothe upper end of the support post 94 as shown particularly in FIG. 2. Aplurality of lateral support members 100 are bolted or otherwiseconnected to the lateral support 98 and in turn provide support for areceptacle 102 having its upwardly facing opening 104 arranged toreceive the dust and tailings that fall through the openings 92 of thevibratory catalyst tray. The receptacle 102 is arranged so that is doesnot phyiscally touch the structure of the vibratory tray and thus doesnot vibrate along with the tray. Any dust and catalyst tailings thatfall into the receptacle 102 will simply be contained until thereceptacle has become sufficiently full that it should be emptied. Thereceptacle 102 is provided with a releasable connector 106 so that thetray can be released from the supports 100 simply by loosening theconnector.

[0060] At the end of the vibratory tray, opposite the electronicvibrator apparatus, is provided a plurality of discharge tubes 108 thatextend downwardly from the respective discharge openings 69. Thesedischarge tubes are arranged to receive elongate flexible tubes 110which are secured thereto by means of a plurality of retainer bands 112.At their lower ends, as shown in FIG. 4, each of the flexible polymertubes 110 is secured to the respective upper end of a drop tube member112 by means of a metal retainer band 114. Each of the drop tubes 112 issecured such as by welding to a transverse structural member 116 so thateach of the drop tubes is maintained in parallel relation and maintainedin optimum spaced relation for dropping catalyist pellets through thebottom opening 118 of each of the drop tubes. The transverse structuralmember 116 secures the respective drop tubes in a particular spaced andoriented relation that matches the spacing and orientation or pattern ofthe reactor tubes to be filled. The drop tubes and the structural member16 thus cooperatively define a charging manifold for simutanousorientation of the drop tubes with respect to the reaction tubes to befilled. For location of the charging manifold relative to the reactortubes, an elongate structural member 120 is connected to the structuralmember 116 such as by welding. A pair of locator pins 122 projectdownwardly from respective extremities of the structural member 120 andhave locator guide projections 124 of smaller dimension than the locatorpins for ease of entering adjacent reactor tubes and for thus locatingthe charging manifold in proper position for dropping catalyist pelletsinto muliple selected reaction tubes. Typically, the charging manifoldwill have ten drop tubes, each associated with a particular flexibletube 110 and thus associated with a respective catalyist transfer slotof the vibratory tray. It should be borne in mind however that thecatalyst loading cart may have more or less catalyst transfer slots andcharging manifold tubes as is suitable for the needs of the user.

[0061] To provide for efficient removal of catalyst dust, which cancontaminate the environmental air of the catalyst loading environment,and to also achieve removal of catalyst tailings, both of which caninterfere with proper operation of the catalytic reactor, the catalystloading cart of FIGS. 1-3 may be provided with a vacuum removal systemsuch as is shown in FIGS. 6-12. For catalyst dust removal, a vent hood126 shown in FIG. 7 may be pivotally mounted to the upper portion of thevibratory tray. The vent hood is pivotal to a position on top of thevibratory tray for dust removal and is pivotal to an out of the wayposition for access to the transfer slots and bottom openings of thevibratory tray such as for the purpose of the cleaning. The vent hood istypically composed of sheet metal and defines side panels 128 and 130that are oriented in angular relation. A handle 132 is fixed to the apexof the vent hood such as by welding and is used for manual pivoting ofthe vent hood. The vent hood is also provided with end panels 134 and136 that are fixed to respective ends of the side panels 128 and 130 andproject beyond the side panel 130 to define end panel support sections138 and 140 having mounting flanges 142 and 144 at respective endsthereof. Hinge members 146 are mounted to the flanges 142 and 144 asshown in FIG. 9 to thus provide for pivotal mounting of the hood on thestructure of the vibratory tray. The end panel 134 is also provided witha tubular vacuum connection 148 to which a vacuum tube will beconnected. During operation, a suitable source of vacuum, such as thevacuum source of a manufacturing facility utilizing a catalytic reactor,will be connected. Thus, most of the catalyst dust that might otherwisebe liberated into the environmental air during the catalyst chargingoperation will be evacuated from the vent hood through the vacuumconnection 148.

[0062] When a vacuum purged dust and tailing system is desired, a vacuumpan may be provided as shown in FIGS. 10-13. The vacuum pan, showngenerally at 150 in FIG. 10, has side panels 152 and 154 to which areconnected end panels 156 and 158 so as to define a generally rectangularenclosure. Mounting flanges 160 and 162 project laterally from thebottom portions of the end panels 156 and 158 and provide for support ofthe vacuum pan by the cart framework in position for receiving tailingsand dust that fall through the multiple openings 92 of the bottom of thevibratory tray. The pan structure also defines downwardly convergingside panel sections 164 and 166 which are connected to the respectiveside panel sections 152 and 154. A triangular end panel section 168extends downwardly from the end panel section 156 and is connectedrespectively to the side pane: sections 164 and 166. These panelsections are assembled so that any dust or tailings that fall into thepan will descend downwardly to a pan bottom 170. A vacuum connection 172is fixed to the end panel section 168 and also provides for connectionof a vacuum tube of a vacuum supply so that dust and tailings from thepan will be transported by the vacuum away from the loading site tosuitable facility for reclamation or disposal. During use, the supportflanges 160 and 162 simply rest on the framework structure of thecatalyst loading cart so that from time to time the pan structure 150maybe removed from the cart and cleaned of any residual catalyst dustthat might be present on the inside surfaces thereof.

[0063] With reference now to FIG. 14, an alternative embodiment of thepresent invention is shown generally at 180 which comprises an catalystloading cart mechanism having a catalyst charging manifold that isadapted for upward and downward movement relative to the vibratory traythereof so as to facilitate catalyst loading operations even undercircumstances where the retractable wheels thereof are permitted toremain extended. This type of catalyst loading apparatus may alsofacilitate elimination of the retractable wheel assembly of a catalystloading cart so that casters or wheels of other types may be physicallyattached to the framework so that the cart is always capable of rollingon the tube sheet surface of a reactor. The casters of the cart can beprovided with brakes to prevent inadvertent movement of the catalystloading cart during a charging operation. The catalyst loading cart 180of FIG. 14 will incorporate a framework structure shown generally at 182which may take the general form shown in FIGS. 1-3. The frameworkdefines a generally rectangular framework base 184 having a pair ofvibrator supports 186 and 188 projecting upwardly therefrom and havingcross members 190 and 192 to which structural components of a pair ofelectronic vibrators 194 are mounted. Vibrator elements 196 and 198 ofthe vibrators are operatively connected to a generally horizontallyoriented vibratory tray so that electronic activation of the vibratorswill induce vibratory motion to the vibratory tray. A hopper 202 iswelded or otherwise fixed to the upper portion of the vibratory tray andwill take the form shown in FIGS. 1-3, having a plurality of internalhopper compartments and being closed by a simple removable or pivotalclosure member 204. The vibratory tray may be of the same configurationand dimension as shown in FIGS. 1-3, having an adjustable weir 206 forcontrolling discharge of catalyst pellets from the multiple compartmentsof the hopper. The vibratory tray structure will also define a bottompanel having a section with a multiplicity of openings such as shown at92 in FIG. 3 for permitting catalyst tailings and dust to droptherethrough into a receiving pan. The vibratory tray will also beprovided with a vent hood such as shown at 208 and a collection panstructure shown at 210. The vent hood and collection pan may both besubject to continuous evacuation via vacuum connection tubes 212 and 214to which vacuum conduits are connected in the same manner as describedabove in connection with FIGS. 7-13.

[0064] For retractable mounting of casters to thus enable the catalystloading cart to rest on its cushioned legs 216 and 218 or to rest oncaster wheels 220 and 222, a pair of caster positioning plates 224 and226 are connected by pivots 228 and 230 to respective transversestructural supports 232 and 234 of the cart framework structure. Acentrally located linear actuator 236 is also fixed at the lower endthereof to the framework 182 and is arranged to drive connectors orlinkages for accomplishing pivoting of the wheel support plates 224 and226 about their respective pivots and thus retract the caster wheels 220and 222 upwardly to permit the cushioned legs 216 and 218 of theframework to rest on the upper tube sheet of the catalytic reactor.Also, if desired, the same type of actuator energized wheel retractionsystem that is shown in FIGS. 1-3 may be incorporated within thecatalyst loading cart of FIG. 14. As a further alternative, if desired,the caster retraction mechanism may be eliminated and the caster wheels220 and 222 may be connected directly to the leg structure of theloading cart framework. For purposes of control the loading cartmechanism 180 is provided with a control housing or consol 238 that mayconveniently take the form shown at 54 in FIGS. 1-3.

[0065] It is considered desirable where the catalyst loading cartmechanism is provided with retractable caster wheels or not, to providea catalyst loading manifold that can be independently raised and loweredto promote the efficiency of the catalyst loading operation. Toaccomplish this feature, the vibratory tray 200 is provided with aplurality of catalyst drop tubes 240 that project downwardly from thevibratory tray and are each in communication with respective catalysttransfer slots of the vibratory tray. The upper ends of a plurality offlexible conduits 242, typically composed of a polymer material, areconnected to each of the drop tubes by means of metal retainer bands 244while the lower ends of the flexible conduits are connected to upwardlyprojecting tubular connectors 246 of a fixed manifold 248 by metalretainer bands or clamps 250. The fixed manifold 248 is immovablyconnected to the framework 182 such as by bolting and is provided with aplurality of downwardly projecting telescoping tubes 251 which aretelescopically received within a plurality of telescoping passages 252of a movable charging manifold 253. The charging manifold, when in itslowermost position, is adapted to rest on the reactor tube sheet 254 asshown in FIG. 14 and serves to conduct dropping catalyst pellets intoselected reactor tubes 255. For guided movement of the chargingmanifold, guide bars or tracks 256 are fixed to framework legs 257 andare movably engaged by a slide member 258 which is fixed to the movablecharging manifold. A linear actuator 259 is interposed between the fixedmanifold 248 and the movable charging manifold 253 and is operative tomove the charging manifold downwardly as needed to position the chargingmanifold in registry with selected reaction tubes and upwardly to permitmovement of the catalyst loading cart between tube charging operations.As the charging manifold is moved upwardly and downwardly thetelescoping tubes 251 maintain their telescoping relationship within themanifold passages 252. For locating the charging manifold in chargingposition with respect to a group of reactor tubes to be simultaneouslycharged with catalyst pellets, the charging manifold is provided with amanifold locator structure 260 having a pair of locator pins 261 thatare in fixed relation with the charging manifold and are adapted to bereceived within reaction tube openings that are located adjacent thereaction tubes to be charged. When the locator pins are inserted intoselected reaction tubes during lowering of the charging manifold intoengagement with the tube sheet the plurality of charging passages,typically 10, will move into charging registry with a like number ofreaction tubes to be simultaneously charged with catalyst pellets. Ifdesired, the manifold locator structure may conveniently take the formshown in FIG. 4.

[0066] For purposes of electrical operation and control, the catalystloading cart of this invention is provided with electronic circuitrywhich is shown by FIGS. 15, 16 and 17, with FIGS. 16 and 17 showing thelayout of circuit components of the control panel and within the controlconsol 54 or 238 as the case may be. As shown in FIG. 15, the electroniccircuitry shown generally at 280 is provided with a disconnect switchassembly 282 through which the circuitry is connected to a suitablesource of electrical energy, such as the power supply system of amanufacturing facility. The circuitry which incorporates a neutralconductor 284 and a positive conductor 286 is provided with a masterfuse 288 which will interrupt the circuit in the event of any poweroverload to thereby protect the circuitry from overload damage and toensure against damage to other electronic components that are controlledby the circuitry. A start and run conductor 290 is connected acrossconductors 284 and 286 and includes a fuse 292 that will interrupt thecircuit in the event of circuit overload. The circuit 290 is alsoprovided with a stop switch 294 which will be manually manipulated bythe user of the equipment when shut down of the circuitry is desired.The circuitry also incorporates a start and run circuit incorporating annormally open start switch 296 which will energize a run circuit 298across a relay contact 300. The run circuit is also provided with aprotective fuse 302 and is connected for energy supply to a controllercircuit 304. The controller circuit is provided with a masterpotentiometer circuit 306 having a potentiometer 308 which is also shownas a panel component of the control panel shown in FIG. 16. The stop andstart switches 294 and 296 are also shown in the panel display of FIG.16. The potentiometer 308 is connected with a mode switch 310 having oneoperative position as shown in full line in FIG. 15 and a secondoperative position as shown in broken line. The mode switch is alsoshown in the inside cover panel display of FIG. 16 where it ispositionable between manual and automatic mode settings. In the brokenline position of the mode switch, the master potentiometer circuit isoperative via conductors 312 and 314, with a resistor circuit 316connected across these same conductors. The master control conductors312 and 314 receive a four volt 20 milliamp dc input signal as shown inFIG. 15.

[0067] The circuitry is also provided with trimmer circuits 318 and 320which are both connected to a controller circuit 322 and connected toneutral conductor across an SCR 324 with the gate voltage of the SCRbeing provided by a gate circuit 326 of the controller circuit. Thetrimmer circuits are provided respectively with potentiometers 328 and330 which control adjustment of the amplitude of the vibration of thevibrators 58 and 60 of FIGS. 1-3 and vibrators 94 of FIG. 14. Vibratortrimmer adjustment is accomplished by controlling electromagnet circuits332 and 334 via the trimmer potentiometers 328 and 330. As mentionedabove, by trimmer adjustment of each of the dual vibrators of thevibratory tray, the characteristics of tray vibration can be controlledto efficiently transfer catalyst pellets along the length of theindividual slots or troughs and to achieve virtually identical catalystdrop time from each of the troughs of the vibratory tray. This featurefacilitates efficient and even loading of catalyst material into thereaction tubes to thereby achieve the result of quite even catalystcompaction within the tubes so that the resulting performance of thecatalytic reactor will be at its optimum level. After the trimmerpotentiometers have been properly adjusted, to vary the catalyst droprate into the reaction tubes, the master potentiometer 308 may beappropriately adjusted to increase or decrease the amplitude of trayvibration and thus the catalyst drop rate. The vibratory apparatus, whencontrolled in the manner shown by FIG. 15, will achieve repeatablequality loading operations well beyond the quality of catalytic reactorloading that can be accomplished even by hand loading operations.

[0068] As mentioned above, one of the objections that can be encounteredin automated catalyst loading operations is that changes in the droptime of catalyst will vary responsive to the decreasing weight of thecatalyst material within the loading hopper. When the catalyst loadinghopper is full of catalyst pellets, the weight of the catalyst materialwill cause the vibratory tray to have small amplitude vibrations(because of the combined weight or mass of the vibratory tray, thehopper and the catalyst contained within the hopper) thereby achieving aparticular catalyst drop rate even though the rate of vibration does notchange. As the weight of the catalyst material within the hopper thendecreases during a loading cycle, as the catalyst in the hopper isdepleted, the amplitude of the vibrations of the vibratory tray willincrease, with maximum vibration amplitude occurring as the hopperchambers become nearly empty. Even though the rate of vibration does notchange, the amplitude of the vibration changes significantly and causesconsequent variation in the drop rate of the catalyst during thecharging cycle. It is desirable, therefore, to provide a suitable systemfor controlling the vibration of the vibratory tray so that theamplitude of the vibratory movement of the vibratory tray remainssubstantially constant during a catalyst loading cycle regardless of thechanges of catalyst weight within the hopper. This feature isaccomplished through the provision of catalyst weight related inputsignals that are then conditioned and provided to the controller circuit304 for controlling the amplitude output of the electronic vibrators 58and 60 responsive thereto. This is achieved in accordance with thepresent invention by providing an accelerometer 336 which is mounted onthe vibratory tray 56 and provides a weight sensitive signal output viaconductors 338 and 340 reflecting the amplitude of tray vibrations.These weight sensitive electronic signals are then processed by a datasignal conditioner circuit 342 which is powered by a 24 volt dc powersupply 344 and provides conditioned output signals via conductors 346and 348 to the control circuit 304 as shown in FIG. 15. During acatalyst loading cycle, the weight responsive signals of theaccelerometer 336 will have characteristics that change during thecomplete catalyst charging cycle. The conditioned, weight responsiveoutput signals received by their controller circuit are then used tovary the operational control of the electronic vibrators 58 and 60. Inthis manner, the vibrators are controlled such that the vibrationalamplitude remains substantially constant from the beginning to the endof a catalyst charging cycle so that the drop rate of catalyst from thevibratory tray will remain substantially constant throughout thecatalyst charging cycle.

[0069] As mentioned above, catalyst material is typically premeasuredinto small bags and is provided at a supply point adjacent the tubesheet of the reactor or in a container on the tube sheet. To chargeindividual reactor tubes by a manual charging procedure, a funnel islocated with its discharge spout inserted into the reactor tube to becharged. The worker will then open a premeasured bag and carefully pourthe catalyst contents thereof into the funnel with pouring beingmanually controlled so that the drop rate of the catalyst is controlledaccording to the drop rate that is desired. Any catalyst dust andtailings that are poured from the bags into the funnel will logicallyfall into the reactor tube being charged. In the event the worker shouldinadvertently drop the catalyst bag, some catalyst material can enterother reactor tubes. When this occurs the improperly filled tubes of thereactor will likely be emptied of catalyst and subsequently properlyrecharged. Should the worker pour the catalyst into the funnel at a ratethat is too slow or too fast the reaction tube being charged will besubject to improper compaction, bridging voids, etc.

[0070] When the catalyst loading cart of the present invention isemployed, it is desirable during catalyst loading operations that thecatalyst loading cart remain located in the vicinity of reactor tubes tobe filled and that it be periodically charged with catalyst pellets. Toreplenish its hopper with catalyst pellets, a suitable means be employedto transport measured quantities of catalyst material from a supplypoint to the catalyst loading cart. It is also important to accomplishtransport of the catalyst material from the supply point to the tubesheet of the reactor and to the catalyst loading cart in such mannerthat inadvertent spillage of catalyst material will not occur. It isalso desirable to provide a system for charging the various compartmentsof the loading cart hopper with precisely measured quantities ofcatalyst pellets so that the production of the charging operation maycontinue at a high level without risking improper hopper charging. Toaccomplish these features, a portable catalyst charging hopper may beprovided as shown generally at 350 in FIGS. 18 and 19. The catalystcharging hopper is basically a rectangular housing structure havingparallel side walls 352 and 354 and parallel end walls 356 and 358.Internally, the charging hopper is provided with a plurality of internalpartitions 358, being the same number of partitions as are providedwithin the hopper 72 shown in FIGS. 1-3 and defining the same number ofinternal hopper charging chambers as the compartments of the hopper ofthe catalyst loading cart. For example, if the hopper of the catalystloading cart is provided with ten internal chambers for feeding catalystto ten elongate troughs of the vibratory tray, the charging hopper willalso be provided with ten internal catalyst chambers. Each of thechambers of the charging hopper will be of identical internal dimensionfor ensuring charging of each of the chambers of the loading cart hopperwith substantially identical volumes of catalyst.

[0071] The bottom of the charging hopper is open but is temporarilyclosed by a slide plate or gate 362 which is movable through an elongateslot 364 of the charging hopper side wall 352 and guided by internalguides within the charging hopper. When the charging gate 362 is fullyinserted into its slot 364, it forms a temporary bottom wall for thecharging hopper and serves to retain catalyst pellets within therespective catalyst chambers 360. The charging gate is movable from theclosed position to the cpen or withdrawn position shown in FIG. 18 todump catalyst pellets from the respective chambers 360 thereof intorespective hopper compartments 76 of the hopper 72. The charging hopperis also provided with a closure panel 366 which is connected by one ormore hinges 368 to the upper end side wall 354. The closure panel 366and the side wall 352 are provided with interlocking latches that willsecure the closure in its closed position after it has been loaded withcatalyst material. For the purpose of catalyst loading, the slide gate362 will be inserted into the side wall slot 364 to its full extent andcatalyst material will be poured into the respective chambers 360.Typically, for rapid but accurate loading of the charging hopper, thechambers 360 will be overfilled and a screed member having a straightedge will be used to scrape away the surplus catalyst. The upper ends ofeach of the partitions 359 are at the same level as the upper ends ofthe side and end walls of the charging hopper. When the charging hopperhas been filled in this manner the catalyst charges of each of thecharging compartments thereof will contain virtually the same volume ofcatalyst pellets.

[0072] As shown in FIG. 19, a lower portion of the charging hopper,below the slide gate opening 364, is inserted into the upper end of thehopper 72 of the catalyst loading cart. After the charging hopper hasbeen so positioned, the slide gate 362 may be grasped and moved to theopen or withdrawn position shown in FIG. 18, thus dropping the catalystmaterial within the hopper chambers 360 into the respective hoppercompartments of the hopper 72. The charging hopper is adapted to becarried by a single worker and incorporates handles 368 and 370 mountedto the respective end walls which facilitate its manual lifting andcarrying.

[0073] By employing the catalyst charging hopper, it becomes unnecessaryto accomplish any catalyst loading immediately above the reactor andunder circumstances when it is possible to inadvertently drop catalystpellets on the reactor tube sheet and into the reactor tubes. A sourceof catalyst pellets will be maintained externally of the circular boundsof the reactor shell, typically in an anteroom located to one side ofthe reactor shell. Workers will locate one or more catalyst charginghoppers in the anteroom and, after closing the sliding gate thereof,will fill each of the multiple chambers thereof with catalyst pellets.These multiple chambers are each of the same dimension and configurationand will each contain a precisely measured volume of catalyst material.After the catalyst charging hopper has been properly filled, its closurewill be closed and latched to secure the catalyst pellets within themultiple compartments thereof. Even under circumstances where a workershould fall while carrying the charging hopper on the reactor tubesheet, the charging hopper will maintain its integrity and contain thecatalyst against potential spillage. The worker will then position thecharging hopper in registering assembly atop the hopper of the catalystloading cart as shown in FIG. 19, after which the worker will puff theslide gate closure to its open position as shown in FIG. 18, thusdumping the measured charges of each of the multiple compartmentsthereof into respective compartments of the hopper of the catalystloading cart. Thereafter, the catalyst charging hopper is returned tothe anteroom, where it is again loaded with catalyst pellets asindicated above in preparation for quick, efficient and accurate loadingof the hopper compartments of the loading cart with precise volumes ofcatalyst pellets. By using a number of catalyst charging hoppers thereaction tube charging operation can be rapidly conducted without in anymanner sacrificing the integrity and accuracy of the reactor chargingoperation. A reactor charging operation, which might require a two weekperiod to complete by hand loading operations, can be done in three tofour days time and with much improved accuracy when a catalyst loadingcart is employed having the capability for simultaneous 10 tubemechanized reactor charging. The labor savings of such a mechanizedreactor charging operation is obvious.

[0074] Referring now to FIGS. 20 and 21, automated apparatus formeasured filing of multi-compartment charging hoppers is shown generallyat 380 and comprises a base structure shown generally at 382 havingvertically oriented support legs 384 and horizontal strut members 386having the ends thereof connected to the support legs. Thus, the basestructure 382 is of generally rectangular configuration. The upperportion of the base structure is defined by a generally horizontalplatform 388 having a pair of parallel rails 390 and 392 fixed thereto.The parallel rails define a guide track for a charging hopper transfertrolley to be discussed in detail hereinbelow. Beneath the horizontalplatform 388 there is provided a catalyst overage chute having inclinedwalls and a bottom opening 396 for directing descending catalyst pelletsfrom the overage chute opening into a catalyst overage receptacle 398that is adapted to rest on a floor 400 or other suitable surface withinthe rectangular enclosure defined by the base structure 382.

[0075] A bulk catalyst hopper 402 is supported above the base structure382 in such manner that catalyst pellets descending from a bottomdischarge opening 404 of the hopper will fall into the multiplemeasuring compartments of a charging hopper 350, described above inconnection with FIGS. 18 and 19. The bulk catalyst hopper 402 isprovided with a bottom closure gate 406 having pivot arms 408 and 410that are pivotally connected to tapered side walls 412 and 414 of thebulk catalyst hopper. The discharge control gate 406 is adapted forcontrolling movement by a gate operator 416 in the form of a linearpneumatic motor. To accommodate catalyst charging hoppers of differingheight, the bulk catalyst hopper 402 is adjustably support so that thedischarge opening at the bottom of the hopper can be selectivelypositioned with respect to the upper portion of a charging hopper. Tofacilitate such adjustable support, a plurality of hopper lift jacks 418are connected to the upper portion of the base structure 382 preferablyextending upwardly from the horizontal platform 388. Although the hopperlift jacks 418 are shown to be of the manually operable variety havingrotatable crank handles 420 for manually controlling operation thereofthe hopper lift jacks may also be of any suitable mechanized variety ifdesired. The hopper lift jacks 418 are provided with hopper supportstruts 422 having the upper ends thereof either connected directly tothe bulk catalyst hopper 402 or, as shown in FIGS. 21 and 22 having theupper ends thereof connected to horizontally oriented hopper supportelements 424 and 426. Thus, as the crank handles 420 of the hopper liftjacks 418 are rotated, the bulk catalyst hopper is raised or lowereddepending upon the direction of handle rotation to thereby position thebottom discharge opening 404 of the hopper as selectively desiredrelative to the charging hopper 350.

[0076] For charging hopper loading, it is desirable to as much aspossible eliminate any manual loading operations that would otherwise berequired so that the charging hoppers may be filled in identically thesame manner during each filling cycle so that at each loading operationthe charging hoppers will be identically filled with accurately measuredvolumes of catalyst pellets. One suitable means for accomplishing thispurpose is to provide a movable charging hopper transfer trolley showngenerally at 428 which incorporates a trolley framework 430 which isadapted to receive the bottom portion of a charging hopper and thusprovide for controlled movement of the charging hopper between a startposition where the charging hopper is available for manual access and afill position where the charging hopper is located to receive dischargeof catalyst pellets from the bottom discharge opening of the bulkcatalyst hopper. The charging hopper framework 430 is provided with aplurality of trolley support wheels 432 which are designed for guidingengagement with the rails 390 and 392 of the trolley guide track. Forcontrolled movement of the transfer trolley 428, a mechanized trolleyactuator 434 is provided which may conveniently be in the form of alinear pneumatic motor having a linear drive shaft 436 thereof connectedin driving relation with the trolley 428. The trolley actuator 434 willhave the capability for linear movement of the trolley 428 between thestart and fill positions of the charging hopper 350 relative to thebottom discharge opening 404 of the bulk catalyst hopper.

[0077] During filling of the charging hopper 350, upon opening movementof the discharge gate 406 of the hopper, it is desirable to ensureadequate settling of the hopper pellets so that each of the catalystmeasuring chambers of the charging hopper will be properly filled tothus define equally measured volumes of catalyst in each of themeasuring compartments thereof. Accordingly, the transfer trolley 428 isprovided with a vibrator 438 which is energized during the filling cycleand which is de-energized when the transfer trolley 428 is at positionsother than the hopper fill position. If desired, the vibrator 438 mayalso be energized during a certain stage of movement of the transfertrolley from the hopper fill position to the start position.

[0078] For control purposes, the charging filling mechanism is providedwith a pneumatic control circuit 440 and an electronic control circuit442. The pneumatic control circuit 440 will have an operator circuitthat is controllably connected to the trolley actuator 434 and a hoppergate actuator circuit 446 that is connected for control of the gateactuator 416. The pneumatic actuator circuits 444 and 446 are controlledby solenoid or other electromechanical valve of the pneumatic controlcircuit via control signals from the electronic control circuit 442. Theelectronic control circuit is provided with appropriate timing circuitsand switching for providing adjustable timing control for the filingcycle of the charging hopper and for sequence control of the hoppertransfer trolley and the discharge control gate of the hopper. Theelectronic control circuitry also includes a start switch 448, a stopswitch 450 and an emergency stop switch 452 thereby allowing operatingpersonnel to manually initiate or stop the charging hopper filling cycleand to manually shut-down the system in the event emergency conditionsshould arise. Preferably, the start, stop and emergency stop switcheswill be in the form of lighted contact buttons thereby enablingoperating personnel to have visual indication of the operating conditionof the charging hopper filling system.

[0079] Since charging hopper filling is accomplished volumetrically, itis desirable to ensure that each of the open topped measuringcompartments of the charging hopper 350 contain a precisely measuredvolume of catalyst pellets when the charging hopper is returned to thestart position by the hopper transfer trolley 428. One suitable meansfor accomplishing this feature is to provide a catalyst leveling elementthat is supported by the hopper structure or the hopper supportframework and is operative upon movement of the charging hopper by thehopper transfer trolley from the fill position to the start position toengage and wipe or brush away any excess catalyst from the upper portionof the charging hopper. As shown particularly in FIG. 20, the catalystleveling element 454 may conveniently take the form of a rotatableleveling brush that is rotated by an electrical drive motor 456. Afterthe hopper fill cycle has continued for a sufficient period of time thatall of the measuring compartments of the charging hopper have beenfilled and excess volume of catalyst is present on the upper portion ofthe charging hopper, the transfer trolley 428 will move the charginghopper from the fill position toward the start position. During initialmovement of the transfer trolley, the charging hopper will be movedrelative to the rotating catalyst leveling element 454 thereby causingexcess catalyst to be brushed away from the upper portion of thecharging hopper and to descend by gravity into the overage chute 394where it is then conducted into the catalyst overage receptacle 398.Although the catalyst leveling element is shown to be in the form of arotatable motor driven leveling brush, it is not intended to limit thespirit and scope of the present invention to this specific structure. Itshould be borne in mind that other leveling elements, such as astationary brush, a mechanical weir, or other suitable leveling elementsmay be effectively utilized without departing from the spirit and scopeof this invention. It is only appropriate from the standpoint of thepresent invention that leveling of the charging hopper by removal ofexcess catalyst be accomplished in the same manner during each loadingcycle. Any suitable leveling apparatus may be utilized that willaccomplish this purpose.

[0080] During dispensing of catalyst from the hopper 402 into thecharging hopper 350 is likely to generate a small quantity of catalystdust simply because of the dust present on the catalyst pellets. Sincethis catalyst dust may be hazardous to the health of workers, it isdesirable to ensure that the presence of catalyst dust is minimized. Forthis purpose, the bulk catalyst loading mechanism 380 is provided with amechanical shroud having side walls 458 and 460, a rear wall 462 and afront wall defined by a pair of door panels 464 and 466 which are bestseen in FIG. 22. The door panels are moveable between an open positionpermitting access to a catalyst charging hopper at the start positionand a closed position preventing access to a charging hopper by operatorpersonnel. The access doors 464 and 466 are provided with a door locksystem 468 which is integrated with the electronic controlled circuitryso that the charging hopper loading apparatus will not operate so longas the access doors are open. When the access doors are closed and anelectrical circuit is completed, which allows operation of the loadingsystem. This feature prevents operating personnel from potential dangeras the hopper transfer trolley moves between its start and fillpositions. The dust shroud thus defines a substantially closed charginghopper filling enclosure 468 to which most of the catalyst dust will berestricted. This enclosure is vented by a source of vacuum V that iscommunicated by a vacuum conduit 470 to a vacuum connector 472 that isreceived at a vent opening 474 of a shroud wall 458. Thus, duringoperation of the charging hopper loading mechanism, the enclosure 468 iscontinuously vented so that any catalyst dust that is liberated into theenclosure 468 is pulled away by the vacuum vent system, therebypermitting workers to have a relatively dust-free environment withinwhich to work.

[0081] As will be readily apparent to those skilled in the art, thepresent invention may be produced in other specific forms withoutdeparting from its spirit scope and essential characteristics. Thepresent embodiment is therefore to be considered as illustrative and notrestrictive, the scope of this invention being defined by the claimsrather than the foregoing description, and all changes which come withinthe meaning and embraced therein.

[0082] In view of the foregoing, it is evident that the presentinvention is one well adapted to attain all the objects and featureshereinabove set forth, together with other objects and features whichare inherent in the apparatus disclosed herein.

[0083] As will be readily apparent to those skilled in the art, thepresent invention may be produced in other specific forms withoutdeparting from it spirit or essential characteristics. The presentembodiment, is therefore, to be considered as illustrative and notrestrictive, the scope of the invention being indicated by the claimsrather than the foregoing description, and all changes which come withinthe meaning and range of the equivalence of the claims are thereforeintended to be embraced therein.

What is claimed is:
 1. A catalyst loading cart for mechanized loading ofcatalyst pellets into the reaction tubes of a catalytic reactor,comprising: (a) a cart framework being selectively positionable relativeto the upper tube sheet of a catalytic reactor to be charged withcatalyst pellets; (b) at least one electronic vibrator being fixed tosaid cart framework; (c) a vibratory tray being connected for vibrationthereof by said electronic vibrator and having a plurality of generallyparallel catalyst transfer troughs through which catalyst pellets aremoved by vibration of said vibratory tray and a plurality of drop tubesthrough which catalyst pellets drop from said catalyst transfer troughsof said vibratory tray; (d) a loading cart hopper being fixed to saidvibratory tray and having a plurality of catalyst compartments eachbeing disposed to feed catalyst pellets into respective catalysttransfer troughs; (e) a catalyst charging manifold having a plurality ofcharging tubes each being disposed in immovable spaced relation andbeing receivable within the reaction tubes of the reactor, (f) aplurality of elongate flexible tubes having upper and lower ends andhaving the upper ends thereof connected to respective drop tubes and thelower ends thereof connected to respective charging tubes; (g) chargingmanifold locator elements projecting from said charging manifold andbeing receivable within selected reactor tubes for location of saidcharging tubes within other selected reactor tubes for charging thereofwith catalyst pellets; and (h) electronic control means being inelectrically controllable connection with said at least one electronicvibrator and being adjustable to achieve vibrator control forsubstantially identical discharge rate of catalyst pellets from each ofsaid catalyst transfer troughs.
 2. The catalyst loading cart of claim 1, wherein said at least one electronic vibrator comprising: (a) a pairof electronic vibrators each having electronic operational circuits andhaving vibratory connection with respective side portions of saidvibratory tray; (b) a pair of adjustable electronic trimmer circuitsbeing electrically connected to respective electronic operationalcircuits of respective electronic vibrators for adjusting the amplitudeof vibration thereof to achieve substantially identical rate ofdischarge of catalyst pellets from each catalyst transfer trough of saidvibratory tray; and (c) a master adjustable electronic vibrator controlcircuit being electronically connected to both of said adjustableelectronic trimmer circuits and being adjustable to vary the rate ofcatalyst discharge from said vibratory tray.
 3. The catalyst loadingcart of claim 1 , wherein: (a) weight responsive signal means generatingelectronic control signals responsive at least in part to the weight ofcatalyst pellets within said loading cart hopper; and (b) controlcircuitry receiving said weight responsive signals and controlling theamplitude of vibration of said electronic vibrator responsive to saidweight responsive signals to achieve a selected rate of catalyst pelletdischarge from said vibratory tray regardless of the weight of catalystpellets within said loading cart hopper.
 4. The catalyst loading cart ofclaim 3 , wherein said weight responsive signal means comprising: (a) anaccelerometer being fixed to said vibratory tray for detecting theamplitude of vibratory motion thereof and providing an amplitude relatedelectronic signal output responsive thereto: (b) a signal conditioningcircuit receiving and conditioning said amplitude related electronicsignal output and providing conditioned weight related output signals;and (c) said control circuitry receiving said conditioned weight relatedoutput signals and controlling operation of Said vibrator to maintainsubstantially constant vibratory amplitude of said vibratory tray as theweight of catalyst pellets within said loading cart hopper is depletedduring a catalyst loading cycle.
 5. The catalyst loading cart of claim 1, wherein: (a) wheel retraction means being moveably connected to saidcart framework: and (b) wheels being connected to said wheel retractionmeans and being selectively positionable by said wheel retraction meansat an extended position for mobile support of said catalyst loading cartby said wheels and a retracted position for support of said catalystloading cart by said cart framework.
 6. The catalyst loading cart ofclaim 5 , wherein: (a) a pair of wheel positioning elements each beingpivotally connected to said cart framework; (b) a pair of wheels beingmounted to each of said wheel positioning elements; and (c) an actuatorassembly being supported by said cart framework and being operative toimpart pivoting movement to said wheel positioning plates forselectively positioning said wheels at said extended and retractedpositions thereof.
 7. The catalyst loading cart of claim 1 , wherein:(a) a vent hood being pivotally mounted to said vibratory tray forlocation above said plurality of catalyst transfer troughs; and (b) asource of vacuum being in communication with said vent hood for removingdust released from catalyst pellets during transfer thereof along thelength of said catalyst transfer troughs.
 8. The catalyst loading cartof claim 1 , wherein: (a) said catalyst transfer troughs each havingperforate bottom wall sections through which catalyst tailings and dustdescend for separation thereof from the catalyst pellets beingtransferred along said catalyst transfer troughs by vibratory action ofsaid vibratory tray; and (b) a catch pan being located immediately belowsaid catalyst transfer troughs and in position for catching any catalysttailings and dust that descend through said perforate bottom wallsections.
 9. The catalyst loading cart of claim 8 , wherein: a source ofvacuum being in communication with said catch pan for removing catalysttailings and dust released from catalyst pellets and descending throughsaid perforate bottom wall sections during transfer of catalyst pelletsalong the length of said catalyst transfer troughs by said vibratoryaction of said vibratory tray.
 10. The catalyst loading cart of claim 1, wherein: said catalyst charging manifold being vertically movablerelative to said vibratory tray to permit efficiency of selectivepositioning of said charging tubes in charging relation with selectedreactor tubes.
 11. The catalyst loading cart of claim 1 , wherein: (a) aplurality of adjustment tubes being disposed in telescoping verticallyadjustable relation with respective drop tubes; (b) a structural membersecuring said adjustment tubes in fixed relation with one another; and(c) means for moving said structural member and thus said adjustmenttubes upwardly and downwardly relative to said drop tubes; and (d) saidflexible tubes of said charging manifold being connected to respectiveadjustment tubes and, upon vertical movement thereof by said adjustmenttubes, causing vertical movement of said charging manifold.
 12. Thecatalyst loading cart of claim 1 , wherein: (a) said loading cart hopperdefining an upwardly facing opening and having a movable closure forsaid upwardly facing opening; (b) a portable charging hopper having thesame number of internal catalyst compartments as said loading carthopper and having an open bottom section adapted to be received incharging assembly with said upwardly facing opening of said loading carthopper; and (c) a slide gate being positionable to close said openbottom of said portable charging hopper for securing catalyst pelletswith said internal catalyst compartments of said portable charginghopper and being selectively movable to an open position for dumpingcatalyst pellets into respective catalyst compartments of said loadingcart hopper.
 13. The catalyst loading cart of claim 12 , wherein: (a)said portable charging hopper defining an upwardly facing opening; and(b) a closure being in movable relation with said portable charginghopper and being positionable for closing said upwardly facing openingthereof.
 14. The catalyst loading cart of claim 12 , wherein: (a) saidportable charging hopper defining a gate opening and gate track; (b)said slide gate being movable through said gate opening and along saidgate track during opening and closing movement thereof.
 15. A method forcharging the multiple reaction tubes of a catalytic reactor having ashell and an upper tube sheet to which the upper ends of a multiplicityof reaction tubes are connected and to charge the reaction tubes withmeasured charges of catalyst pellets, comprising: (a) locating on theupper tube sheet and within the bounds of the reactor shell of thecatalytic reactor a catalyst loading cart having a multiple compartmentfeed hopper and a multi trough vibratory tray operated by a pair ofelectrically energized vibrators and having a plurality of drop tubesfor simultaneous dropping of catalyst pellets into a plurality of thereaction tubes of the reactor; (b) controllably vibrating the vibratorytray of the catalyst loading cart for controlled transfer of catalystpellets along said multiple troughs for dropping thereof through saiddrop tubes and into the reaction tubes at a predetermined drop rate; (c)locating a catalyst charging hopper at a catalyst source outside thebounds of said upper tube sheet, said catalyst charging hopper havingthe same number of charging compartments as the number of compartmentsof said feed hopper; (d) filling all of said measuring compartments ofsaid charging hopper with catalyst pellets; (e) closing said charginghopper; (f) manually transporting the filled charging hopper to saidcatalyst loading cart and placing said charging hopper in chargingassembly with said feed hopper, with the compartments of said charginghopper in charging registry with the compartments of the feed hopper;(g) simultaneously releasing the catalyst of said charging compartmentsinto the compartments of said feed hopper; and (h) returning saidcharging hopper to said catalyst supply site for refilling thereof withcatalyst.
 16. The method of claim 15 , comprising: (a) providingelectronic signals responsive to the weight of catalyst within said feedhopper; and (b) adjusting the electrical supply to said vibratorsresponsive to said weight related electronic signals to maintain theamplitude of vibrator movement substantially constant at all conditionsof catalyst weight within said feed hopper.
 17. The method of claim 15 ,comprising: (a) measuring the amplitude of movement of said vibratorytray with said feed hopper full of catalyst and providing electronicsignals responsive to the measured amplitude; (b) adjusting theelectrical supply to said vibrators responsive to weight responsivechanges to said measured amplitude to maintain the amplitude of movementof said vibratory tray substantially constant at all conditions ofcatalyst weight within said feed hopper.
 18. A method for filling amulti-compartment catalyst charging hopper with a measured quantity ofcatalyst with each measuring compartment thereof containingsubstantially identical volumes of catalyst, comprising: (a) providing abulk catalyst hopper having a discharge outlet and a discharge gatemovable to an open position to permit discharge of catalyst into saidcharging hopper and a closed position blocking discharge of catalystfrom said discharge outlet; (b) positioning a charging hopper at a fillposition to receive discharge of catalyst from the discharge outlet ofthe bulk catalyst hopper; (c) opening said gate for a sufficient periodof time to overfill each of the measuring compartments of said charginghopper, (d) closing said gate; (e) removing excess catalyst from each ofthe measuring compartments of the charging hopper; and (f) moving thecharging hopper from said fill position.
 19. The method of claim 18 ,wherein said step of positioning comprises: (a) placing an emptycharging hopper on a movable trolley of said bulk hopper, with themovable trolley located at a start position; (b) moving the movabletrolley to a loading position where the catalyst charging hopper islocated to receive catalyst from the bulk hopper discharge outlet; andsaid charging hopper has been overfilled, returning the movable trolleyto the start position.
 20. The method of claim 18 , comprising:vibrating the charging hopper during filling thereof to settle catalystin the multiple measuring compartments of the charging hopper and toensure complete filling of each of the multiple measuring compartmentsthereof.
 21. The method of claim 18 , wherein said moving stepcomprising: (a) moving a filled charging hopper from said fill position;and (b) during said moving of the filled charging hopper applying awiper to excess catalyst present on the charging hopper to wipe away theexcess, thus leaving the charging hopper with accurately measuredvolumes of catalyst in each of the multiple measuring compartmentsthereof.
 22. The method of claim 21 , wherein the wiper being a brush,the method comprising: brushing away excess catalyst.
 23. The method ofclaim 21 , wherein the wiper being a movable brush, the methodcomprising: moving the movable brush against the excess catalyst forbrushing away excess catalyst.
 24. The method of claim 21 , wherein thewiper being a rotatable brush, the method comprising: rotating therotatable brush against the excess catalyst during return of the trolleyfrom the fill position to the start position for brushing away excesscatalyst.
 25. The method of claim 18 , wherein a catch receptacle islocated beneath said discharge outlet of said bulk hopper, said methodcomprising: (a) during said moving step directing removed excesscatalyst into the catch receptacle; and (b) periodically returningexcess catalyst from the catch receptacle to the bulk hopper.
 26. Themethod of claim 18 , wherein the bulk hopper mechanism defining asubstantially closed filling chamber, said method comprising: removingair borne catalyst dust from the substantially closed filling chamber.27. A method for filling a multi-compartment catalyst charging hopperwith a measured quantity of catalyst with each measuring compartmentthereof containing substantially identical volumes of catalyst,comprising: (a) providing a bulk catalyst hopper having a dischargeoutlet and a discharge gate movable to an open position to permitdischarge of catalyst into said charging hopper and a closed positionblocking discharge of catalyst from said discharge outlet; (b)positioning a charging hopper on a movable trolley at a start positionand moving the trolley and charging hopper to fill position to receivedischarge of catalyst from the discharge outlet of the bulk catalysthopper; (c) opening said discharge gate for a sufficient period of timeto overfill each of the measuring compartments of said charging hopper;(d) closing said discharge gate; (e) moving said movable trolley withthe overfilled charging hopper thereon from said fill position to saidstart position; and (f) during said moving causing contact of excesscatalyst of the overfilled charging hopper with a brush thus brushingexcess catalyst from each of the measuring compartments of the charginghopper.
 28. Apparatus for filling a multiple compartment catalystcharging hopper such that each of the multiple measuring compartmentsthereof contain substantially identical volumes of catalyst, comprising:(a) a bulk hopper having a discharge outlet; (b) a discharge gate beingmovable to an open position permitting discharge of catalyst from saiddischarge outlet and being movable to a closed position blocking thedischarge of catalyst from said discharge outlet; (c) a trolley adaptedfor support of a charging hopper and being movable from a start positionwhere the charging hopper is manually accessible to a fill positionwhere the charging hopper is positioned for receiving catalyst from saiddischarge outlet; (d) means for moving said trolley from said startposition to said fill position and for returning said trolley from saidfill position to said start position; and (e) means for removing excesscatalyst from the charging hopper during said returning of said trolleyfrom said fill position to said start position.
 29. The apparatus ofclaim 28 , wherein; (a) a track extending from said start position tosaid fill position; (b) said trolley having wheels having rollingengagement with said track; and (c) said means for moving said trolleybeing a linear motor mounted to said apparatus and having drivingconnection with said trolley.
 30. The apparatus of claim 28 , whereinsaid means for removing excess catalyst from said catalyst charginghopper comprising; a brush disposed for engagement with excess catalyston said catalyst charging hopper during movement of said trolley fromsaid fill position to said start position.
 31. The apparatus of claim 30, wherein: a vibrator being mounted to said trolley and, when energized,causing vibration of said trolley for settling catalyst within each ofthe multiple measuring compartments of the catalyst charging hopper. 32.The apparatus of claim 28 , comprising: (a) a base structure; and (b)means adjustably supporting said bulk catalyst hopper on said basestructure and being adapted for controlled elevational positioning ofsaid bulk catalyst hopper relative to said base structure.